Ladies&#39; stretch heelless stockings



April 16, 1968 c. A. BERRY 3,377,826

LADIES STRETCH HEELLESS STOCKINGS Filed Feb. 27, 1967 INVENTOR. C LYbE- A. BERRY ATTORNEYS United States Patent 3,377,826 LADIES STRETCH HEELLESS STOCKHNGS Clyde A. Berry, Valdese, N.C., assigno'r to Pilot Research Corporation, Valdese, N.C., a corporation of North Carolina Continuation-impart of application Ser. No. 531,248,

Mar. 2, 1966. This application Feb. 27, 1967, Ser.

5 Claims. (Cl. 66-178) ABSTRACT OF THE DISCLOSURE Ladies sheer seamless stretch stockings are produced in no more than two sizes which are adapted to fit the complete normal range of leg and foot sizes. The stocking is knit of a fine denier non-torque self-crimping type yarn and then finished without the usual heel projection to provide a sufiiciently high degree of uniform stretchability to the stocking that the size and shape of the foot of the wearer shapes the fabric into a conforming heel and foot configuration when the stocking is worn.

This application is a continuation-in-part of my copending application Ser. No. 531,248, filed Mar. 2, 1966, now Patent No. 3,310,966, and relates generally to ladies sheer seamless stretch stockings. More particularly, this invention also relates to ladies stretchable heelless stockings of the seamless tube type having sufiicient stretchability to fit a Wide range of leg and foot sizes, but in which stretchable non-torque yarns are used to achieve stretchability in the fabric.

As pointed out in my copen'ding application, ladies non-stretchable tube type stockings have become quite popular in the last few years, primarily because of their low cost. These stockings are normally produced in a full range of sizes by knitting a non-stretchable monofilament nylon yarn to forma substantially straight tube at a high production rate The tubes are thereafter closed at the lower end, as by a sewing operation, and then boarded (before or after dyeing as is well known) to set the tube into a conventional stocking shape; i.e., a relatively wide knee area tapering down through the calf area to a relatively narrow ankle area and terminating in a foot shaped with a distinct heel pocket heat set therein.

The invention of my copending application pertains to a heelless tube stocking which is knit of yarn having sufficient liveliness or torque so that the lower portion of the stocking (that portion which normally covers the foot and ankle) has sufficient stretchability that the foot of the wearer will stretch the fabric and form its own heel pocket whereby the stocking will fit a wide size range. In this type stocking, fabric stretcha-bility is achieved due to the stitch loops in the fabric being inclined or distorted from their normal vertical direction by alternately knitting yarns of opposite torque, and prior to my invention it was necessary to produce torque yarn stretchable stockings in at least three sizes in order to fit the entire size range.

Stretchable ladies stockings have also been produced from stretchable non-torque yarns such as, for example, self-crimping yarns or those which have an inherent ability to crimp, curl or coil when heated and are produced from a two-component yarn, one component of which has a greater residual shrinkage than the other. Heretofore, when producing tube stockings from this type of selfcrimping yarn wherein a heel pocket is boarded into the tube, it has been customary to produce such stockings in six to eight sizes because of the limited amount of stretch ability achieved by this yarn.

With the foregoing in mind, it is an object of the present invention to provide ladies sheer seamless tube stockings which are knit of fine denier self-crimping type yarn and which will =fit a wide range of foot and leg sizes.

The stocking of this invention is characterized by the absence of the usual knitted or shaped heel projection and by the presence of substantially uniform stretch characteristics throughout the straight heel and foot area of the stocking. Instead of the usual heel projection, the heel and foot portion of the stocking comprises an extension of the leg portion which is substantially in line with the leg and of substantially uniform width throughout. Further, the stocking is characterized by having a final length after boarding and relaxation which, unlike other types of stretch stockings, closely approximates the length the stocking assumes when placed on the leg of the wearer and which has an abnormally narrow width. The straight heelless lower portion of the stocking is capable of stretching from three to four times its relaxed width, in a coursewise direction, so that the length and shape of the foot of the wearer may shape the fabric into a conforming heel and foot configuration when the stocking is worn, result in in a surprisingly good and comfortable fit in both the relatively wide heel and narrow ankle areas.

Some of the objects of the invention having been stated, other objects will appear as the description proceeds when taken in connection with the accompanying drawings, in which:

FIGURE 1 is a side elevation of a seamless tube in fiattened condition, with the central portion broken away, knit in accordance with the present invention and having the lower toe end portion closed with an arcuate seam;

FIGURE 2 is a side elevation of the boarded stocking of the present invention in flattened condition and illustrating its long slim appearance after it has been removed from the boarding form for some time, the dotted line along the right-hand side illustrating the wider configuration it has when it is first removed from the boarding form; and

FIGURE 3 is a greatly enlarged fragmentary view of the fabric in the area enclosed by the dotted rectangle 3 in FIGURE 2 and illustrating the manner in which the yarn is irregularly distorted in the stitch loops, when the fabric is in partially stretched condition.

The stocking blankshown in FIGURE 1, is knit on a circular knitting machine and includes a turned welt 10 and shadow welt 11 which are usually knit of heavy denier multifilament self-crimping type yarn, of about 45 denier. The welt 1th and shadow welt 11 may be knit of either a different type of stretchable yarn or of a nonstretchable yarn. Then a substantially straight tubular portion T is knit of self-crimping type thermoplastic yarn within the range of about 10 to denier, preferably 15 denier. The yarn is preferably self-crimping nylon of the type produced by Du Font and marketed under its trademark Cantrece. This self-crimping yarn may be monofilament, as shown, or it may have up to three or four filaments. If desired, the size of the stitch loops may be gradually reduced in the conventional manner as the tubular portion T is knit, from the shadow welt downwardly.

At the lower end of the tubular portion T, a toe end section 12 is preferably knit of a heavy denier yarn, such as denier multifilament self-crimping nylon, to provide reinforcement at the toe end of the stocking, in a manner to be presently described. The self-crimping type yarn of which the stocking of this invention is knit is of the non-torque type since it may be knit on a single feed machine without causing a twisting of the stocking blank. With this type of yarn, the stretch is imparted to the fabric by irregular distortion of the yarn in the stitch loops. This is in contrast to the stretch provided by torque yarn, where the stitch loops incline in a direction corresponding to the torque direction.

The lower end of the stocking blank is then closed by an arcuate line of stitching or overedge seam extending across the toe end section 12, as indicated by the dotted line 13 in FIGURE 1. It is preferred that the stocking blank be turned wrong side out before the seaming operation. Then, as the overedge seam 13 is applied along the lower end of the stocking blank, the surplus fabric, indicated in dotted lines in FIGURE 1, is cut away in a conventional manner by the seaming machine. The stocking blank is then turned right side out so that the seam 13 is disposed on the inside of the stocking blank.

The stocking blank (FIGURE 1) may then be finished using conventional procedures. However, a novel boarding form without the usual heel projection is utilized to shape and form the stocking of the present invention. The novel boarding form is formed of relatively thin sheet metal which is shaped to substantially conform to the configuration of the boarded stocking, as shown in solid and dotted lines in FIGURE 2. The stocking is drawn onto and uniformly stretched on the boarding form, and while in this condition the stocking is subjected to heat-setting treatment, usually in a steam pressure cabinet for a predetermined time interval.

The finishing of the stocking may include the recommended pre-steaming before dyeing. The steaming and dyeing may be successively carried out with the stockings in suitable dye bags, or the stockings may be dyed while on the novel boarding form and in a continuous process.

As the stocking blank is drawn onto the novel boarding form, the stocking is stretched down on the board to a predetermined extent and thereby the stitch loops throughout the extent of the tubular stretchable portion T are in substantially uniformly distorted condition during the heat-setting process. Since the boarding form does not have a heel pocket forming bulge, there is no excessive stretching of the stocking on the boarding form while the boarding process is taking place with the result that the stretchability of the fabric is not reduced during the boarding operation, as would be the case when a tube stretch stocking is pulled onto and boarded on a conventional boarding form having the usual heel projection. When the stocking is removed from the boarding form, it has the usual heeless configuration (FIGURE 2) heatset therein.

The stocking is illustarted in solid lines in FIGURE 2 as it appears after having been removed from the wider boarding form and allowed to relax for about twelve to twenty-four hours. The stocking has drawn inwardly in a coursewise direction to a considerable degree. For example, the lower straight heel and foot forming portion of the boarding form (and the stocking when it is first removed therefrom) measures three and three-forths (3%) inches in width. After relaxing for twelve to twentyfour hours, this same portion measures two and oneeighth (2%) inches across. During this relaxing period, substantially all of the contraction takes place in the coursewise direction. In the walewise direction, only a very limited amount of contraction takes place after the hose is removed from the form. For example, the stocking measures thirty-six (36) inches from top to bottom when first removed from the form and after it is relaxed, it measures thirty-five (35) inches from top to bottom. As a result of the foregoing, substantially all of the stretch achieved with the stocking is in the coursewise direction.

Surprisingly, this narrow lower portion of the stocking will stretch in a coursewise direction to a width of eight and one-half to nine (8 /2 to 9) inches, an amount sufficient to permit the stocking to be easily drawn over the heel of the wearer while readily fitting the foot, heel and much narrower ankle portion. This ability of the stocking to stretch in a coursewise direction to three to four times its relaxed width can be contrasted to the torque yarn heeless stocking of my said copending application which will stretch about two times its relaxed width.

The relaxed stocking shown in solid lines in FIGURE 2 will be described and for convenience of description, reference lines have been applied thereto. The line A indicates the extent of the stretchable tubular portion of the stocking which extends from the lower edge of the shadow welt 11 to the upper edge of the closed toe end portion D. The stretchable tubular portion A is divided into an upper half or calf, knee and thigh portion B and a substantially shorter lower half or foot portion C. The upper half B is adapted to fit the calf, knee and thigh area of the wearer while the lower half C is adapted to fit the foot, heel and ankle of the wearer.

The front edge of the boarded and relaxed stocking (FIGURE 2) defines a substantially straight line from the open top edge of the welt 10 to the lower end of the stretchable tubular portion A with a slight inward curve in the toe end portion D. The lower closed end, along the seam 13, curves upwardly along an arcuate path. The rear edge of the lower half C defines a substantially straight line parallel with the front edge so that the flattened tubular lower half C is substantially the same witdth throughout. This straight lower half C provides a heelless portion adapted to fit the foot, heel and ankle of the wearer. The rear edge of the upper half B gradually curves outwardly, inwardly and then outwardly to provide a suitable shape to aid in adapting this portion of the stocking to fit the calf, knee and thigh of the wearer. Thus, the upper half B progressively increases in width from the bottom to the top and the Welt 1G and shadow welt 11 are of substantially a uniform width.

Due to the fiat nature of the boarding form, heat-set creases are formed along the front and rear edges of the stocking during the boarding operation. These front and rear creases are readily discernible in the finished stocking and may serve as an aid in properly positioning the stocking on the leg.

As shown in the courses C-20 and C-21 of FIGURE 3, the yarn Y in each stitch loop is irregularly distorted, due to the crimp, curl or coil in the yarn. When the fabric is completely relaxed, the yarn in the stitch loops distorts to a much greater extent then that illustrated in FIGURE 3. The fabric has been illustrated in FIGURE 3 as being in a partially stretched condition to enable one to more easily follow the stitch construction.

It is preferred that the upper half B of the tubular portion of the stocking be shaped along its rear edge to generally conform to the configuration of the upper portion of the leg so that this upper rear portion generally conforms to the shape conventionally imparted to this portion of ladies stockings. This shaping of the rear upper edge of the stocking of the present invention aids in properly positioning the stocking on the leg, since there is no shaped foot and heel to aid the wearer. However, it is to be understood that the contour of the stocking can be varied as desired; e.g., it could be substantially the same width throughout, from the toe end D through the turned welt 10, or it could be slightly tapered from top to toe, it being of primary importance only that the lower portion of the stocking maintain its generally tubular character and that the heel area be devoid of the usual excessively shrunken portion at the axle and excessively stretched portion at the heel pocket.

While the stocking is shown as being knit with plain stitches, it is to be understood that it could also be knit with other types of stitches. For example, it could contain tucks formed in a pattern with the plain stitches, in what is known as a micromesh pattern.

In the drawings and specification there has been set forth a preferred embodiment of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.

I claim:

1. A ladys boarded, relaxed, sheer, seamless, stretch,

tube stocking adapted to fit a Wide range of foot and leg sizes, said stocking comprising an open upper end having a welt formed thereon, a closed lower toe end, and a heelless tubular portion therebetween, said tubular portion being knit of courses of a stretchable non-torque thermoplastic yarn not in excess of about 30 denier, at least that lower portion of said tubular portion adapted to fit the foot, heel and ankle being heelless and of substantially the same width throughout, and the yarn in the stitch loops of said lower portion providing a substantially high degree of coursewise stretchability to the fabric throughout said lower portion to thereby permit the stocking to be drawn over the heel of the wearer and to readily conform thereto.

2. A ladys stretch stocking according to claim 1 wherein said stretchable non-torque thermoplastic yarn is of the self-crimping type which is produced from a twocomponent yarn, one component of which has a greater residual shrinkage than the other.

3. A ladys stretch stocking according to claim 1 wherein the heelless lower portion is capable of being stretched three to four times is relaxed width in a coursewise direction.

4. A lady's stretch stocking according to claim 3 wherein the heelless lower portion is substantially two inches wide in relaxed condition and will stretch to about nine inches.

5. A ladys stretch stocking according to claim 4 wherein the heelless lower portion is substantially less than onehalf the overall length of said tubular portion.

References Cited UNITED STATES PATENTS 2,699,056 1/1955 Margulies -66178 X 2,825,215 3/1958 Backreus 66178 2,919,534 1/1960 Bolinger et al. 2872 X 2,968,937 1/1961 Margulies 66-4 85 X 3,041,706 7/1962 Brornley et al. 28-42 X 3,140,525 7/1964 Lamb 2872 X 3,333,314 8/1967 Harris 66-178 FOREIGN PATENTS 950,428 2/1964 Great Britain.

MERVIN STEIN, Primary Examiner.

R. FELDBAUM, Assistant Examiner. 

